Gusseted and Recessed-Leg Area Corner Caps

ABSTRACT

A three-way corner cap having three legs joined to a central corner region. Each leg includes an arcuate region extending along the length of the leg and a planar gusset projecting outwardly from and connecting each side edge of the arcuate region, with at least one leg also including a recessed area integral with the gusset along each side edge.

REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 11/138,570 filed May 26, 2005, for “Gusseted and Recessed-Leg Area Corner Caps”.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to devices used in wall board joint and corner finishing, and, more particularly, to corner caps that feature gussets and/or recessed areas that provide desirable durability and installation properties.

2. Description of the Related Art

Plastic corner pieces and strips of plastic or metal are commonly used by residential and commercial builders to finish corners at intersections of wallboard (drywall such as Sheetrock™, gypsum board, etc.), especially when a “rounded corner” appearance is desired.

Many wall edging and corner finishing systems involve the use of a corner cap in combination with flanged metal or plastic strips which act as a corner bead. For example, the flanges of a strip are nailed to adjacent drywall on an “outside corner” (defined by the obtuse intersection of two wallboard planes) and interconnected with (or adhered to) a corner cap. The combination of the strips and corner cap would then be ready for spackling, painting, or other decretive treatment. While such systems may be suitable for their intended purpose, they also can suffer from some disadvantages.

Metal strip surfaces are prone to damage (e.g., deformations, such as kinks or dents) that typically results in the strip having to be replaced or restored, which can be unnecessarily expense and time consuming. Nonetheless, their use remains fairly widespread in the trade. Thus, it is important to ensure that metal strip installation and interconnection to, or adherence with, a corner cap is done correctly the first time to avoid excess handling or manipulation. Moreover, depending upon the workmanship of the contractor, the trueness and alignment of the intersecting wallboard, and manner in which the strip is interconnected or attached to corner cap, the strip and corner cap may not have an ideal fit.

Furthermore, problems with the fit between a strip and corner cap can be exacerbated by having a relatively small and thin area (such as a small “tongue” projecting out from the end of a corner cap leg and) with which a strip must be aligned or joined.

Therefore, there is a need for simple corner caps that are durable, provide a good fit even upon imperfectly formed corner intersections of wallboard, and that provide desirable installation properties for, or forgive the imperfect placement of, edging strips.

SUMMARY OF THE INVENTION

In general, the invention provides a new and improved corner cap featuring three legs joined at a central corner region, with each leg having an arcuate region extending along its length, planer gussets disposed upon the side edges of each leg, and at least one recessed area over which a strip may be placed.

In one embodiment of the invention, at least one of the gussets extending outwardly from the edges of the legs is wider than the width of the arcuate portion to provide added surface area to the corner cap that is useful in adhering the cap to a less than perfect corner and to provide a larger surface with which to abut an edging strip or bead.

In another embodiment of the invention, one or more of the planer gussets defines a triangular region between legs of the corner cap. In other words, the gusset width varies along the length of each leg.

In another embodiment of the invention, one or more gussets are integral with two or more legs of the corner cap, including any recessed areas of the legs.

While corner caps of the invention commonly are made to include three legs that are in perpendicular arrangement relative to each other (i.e., disposed at 90° angles), other angles are, of course, also useful.

Various other purposes and advantages of the invention will become clear from its description in the specification that follows. Therefore, to the accomplishment of the objectives described above, this invention includes the features hereinafter fully described in the detailed description of the preferred embodiments, and particularly pointed out in the claims. However, such description discloses only some of the various ways in which the invention may be practiced.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. is a side elevational view illustrating a three way perpendicular-leg corner cap of the invention.

FIG. 2. is a perspective view of the corner cap illustrated in FIG. 1.

FIG. 3. is a rear perspective view of a 135° corner cap of the invention.

FIG. 4 is a front perspective view of the corner cap illustrated in FIG. 3.

FIG. 5 is a side elevational view of a second embodiment of the invention.

FIG. 6 is a perspective view of the embodiment illustrated in FIG. 5.

FIG. 7 is a partially cross-sectional, elevational illustration of the embodiment shown in FIG. 6 as taken along line 7-7 and viewed in the direction indicated.

FIG. 8 is a side elevational view of a corner cap of the invention as it would appear in combination with two strips.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention generally relates to a three-way corner cap having three legs joined together in a central corner region. Each leg includes a central, arcuate region extending along the length of the leg and a planar gusset projecting outwardly from and connecting each side edge of the arcuate region, with one or more legs including a recessed area located between the end of the leg and the central corner region to accommodate the placement of a strip.

The gussets of the invention provided added durability to the corner cap, particularly in applications involving installation on less-than-perfectly formed or aligned wall corners.

Turning to the figures, wherein like number designate like elements, FIGS. 1 and 2 illustrate a three-way corner cap in which the gussets are wider than the arcuate region of at least one leg.

The corner cap 2 is formed from a single piece of plastic and includes three perpendicular legs 4 (only two of which are visible in this view) joined together in a central corner region 6. Each leg includes a central, arcuate region 8 extending along the length of the leg 4 and a planar side gusset 10 projecting outwardly from each side edge 12 of the arcuate region 8. Unlike a flanged corner cap of the related art, the gussets of the present invention fill the area between each leg. This provides improved strength, and, consequently, durability of the corner cap 2. Openings 13 provide a place for nails or other fasteners to be driven through the corner cap 2 without cracking or otherwise damaging the cap during installation.

In this embodiment, the corner cap 2 provides for advantageous installation to wallboard junctions by having the arcuate region 8 of at least one leg 4 (or, in this case all three) possess a width W1 that is less than the width W2 of each adjoining side gusset 10. In other words, each gusset 10 provides an area that is wider than the width of an adjoining leg 4. Thus, an edging strip that is slightly out of alignment with the leg of the corner cap can still be adhered to the corner cap instead of directly to the wallboard. Moreover, the relatively wide gussets 10 provide added surface area for more strongly adhering to even an imperfect wallboard corner.

Preferably, the corner cap 2 has at least one leg 4 that includes a recessed area 14 located at an outermost end 16 of the central arcuate region 8 of leg 4. The recessed area 14 is integral with, and has a thickness that is substantially the same as, the remaining portion of the leg 4. Moreover, the recessed area 14 is integral with the gussets 10. These features make the recessed area 14 less prone to chipping or breaking than would be a separate “tongue” of reduced thickness extending from an outermost end of a leg.

The recessed area 14 also is designed to provide easier (and therefore faster) fitting between an edge strip and the corner cap 2. Thus, a strip placed over the recessed area 14 prior to being nailed or otherwise adhered to the corner cap tends to be in better alignment with the corner cap 2 upon finishing of the installation.

As shown in FIG. 2, at least two of legs 4 can have recessed areas 14 starting from a location on the two legs about two-thirds of the distance from the central corner 6 to an outermost end 16 of the arcuate region 8. Thus, a better fit between the corner cap and two edging strips may be had.

Turning to a second embodiment of the invention, a three-way corner cap having a 135° angle (rather than three 90° legs as shown above) is illustrated in FIGS. 3 and 4. This corner cap 20 includes one leg 22 with a recessed area 24 and two other legs 26 that meet at a central corner region 28. Extending from the side edges 30 of the legs 22 and 26 are planer gussets 32. As illustrated, two of gussets 34 have a width W3 that are wider than width W4 of legs 26.

The corner cap 38 shown in FIGS. 5 and 6 preferably is formed from a single piece of plastic and includes three perpendicular legs 40 joined together in a central corner region 42. Each leg includes a central, arcuate region 44 extending along the length of the leg 40 and a planar gusset 46 projecting outwardly from each side edge 48 of the arcuate region 44. In this embodiment, each planer gusset 46 defines a triangular area 50, which, in some applications, has been found to provide better cohesion between the corner cap 38 and abutting strips (see FIG. 8). Single openings 52 provide a place for nails or other fasteners to be driven through the corner cap 38 and into the substrate underneath.

Preferably, the corner cap 38 has at least one leg 40 (in this case all three) that includes a recessed area 54 located either at an outermost end 56 of the central arcuate region 44 of leg 40 or along the entire length of the leg up to the central corner region (i.e., recessed area 55). Moreover, in addition to this corner cap configuration (with three perpendicular legs defining a corner region in which each leg is disposed at a 90° legs angle to each other as shown in FIG. 5), other leg arrangements are possible (e.g., a 135° angle similar to the cap shown in FIG. 4).

FIG. 7 is a partially cross-sectional, elevational illustration of the embodiment shown in FIG. 6 as taken along line 7-7 and viewed in the direction indicated by the arrows. In this view, the recessed area 54 can be more clearly seen to have a thickness that is substantially the same as the remaining portion of the leg 40. Moreover, the recessed area 54 can also clearly be seen to be integral with both the remaining portion of the leg 40 and with gussets 46.

FIG. 8 schematically depicts the installation of a corner cap 60 with two strips 62 and 64. Strip 62 is disposed atop recessed area 66 (shown in phantom line) of leg 68. Similarly, strip 64 is disposed over leg 70, except that the entire leg is recessed relative to corner region 72. This allows strip 64 to directly abut corner 72 at a lip 74

Various changes in the details and components that have been described may be made by those skilled in the art within the principles and scope of the invention herein described in the specification and defined in the appended claims. Therefore, while the present invention has been shown and described herein in what is believed to be the most practical and preferred embodiments, it is recognized that departures can be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent processes and products. 

1. A three-way corner cap that is engaged by a strip comprising: three legs joined to one another, a selected two of said legs having a first end nearer the others of said legs and a second end farther from the others of said legs, and said first and second ends being spaced from one another along a predetermined direction, said selected two legs including a first section which extends from said first end to a location between said first and second ends, and said selected two legs further including a second section which extends from said location to said second end and defines a recessed shoulder on each of said selected two legs at said location; a third leg having a first end nearer the others of said legs and a second end farther from the others of said legs, said first and second ends being spaced from one another along a predetermined direction and defining an area that extends from said first to said second end, is recessed relative to said first section but not said second section of the selected two of said legs, and is engaged beneath said strip; a gusset extending from one of said sections to the other across said shoulder and being fast with each of said sections of said selected two of said legs; and a gusset extending from said first end to said second end of said third leg and across to and being fast with each of said sections of said selected two of said legs.
 2. The cap of claim 1, wherein said gussets are substantially triangular.
 3. The cap of claim 1, wherein said selected two of said legs have an arcuate portion extending along said predetermined direction.
 4. The cap of claim 3, wherein said selected two of said legs are arcuate from said first end to said second end.
 5. The cap of claim 3, wherein said arcuate portion has a first width as considered transverse to said predetermined direction and said gusset has a second width as considered transverse to said predetermined direction, said first width being less than said second width.
 6. The cap of claim 1, wherein a first one of said legs and a second one of said legs radiate from a region which is substantially centrally situated with respect to said first and second legs.
 7. The cap of claim 6, wherein said region is substantially centrally situated with respect to all of said legs.
 8. The cap of claim 1, wherein said first and second sections have substantially the same thickness.
 9. The cap of claim 1, wherein said gussets are provided with an opening for a fastener, said opening constituting the sole opening in said gussets.
 10. The cap of claim 1, wherein said legs are substantially perpendicular to one another.
 11. The cap of claim 1, wherein said gussets are substantially planar.
 12. The cap of claim 1, wherein said legs and said gussets are formed from a single piece of plastic. 